UNIVERSAL HEADACHE RACK
MID SIZED TRUCKS (EXCL TOYOTA TACOMA)
PARTS LIST:
1 Mid-Sized Headache Rack
1 Driver/Left Side Bracket
1 Passenger/Right Side Bracket
4 12-1.75mm x 40mm Hex Bolts
10 12mm x 37mm x 3mm Flat Washers
2 10mm Universal J-Bolts
6 10-1.5mm x 40mm Hex Bolts
6 10mm x 34mm x 3mm Large Flat Washers
12 10mm x 24mm x 2.2mm STD Flat Washers
6 10mm Lock Washers
6 10mm Hex Nuts 4 12mm Lock Washers
4 12mm Hex Nuts
Passenger/Right
Mounting Bracket
(2) 10mm Universal
J-Bolts
Driver/Left Mounting Bracket
PROCEDURE:
REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS
CAREFULLY BEFORE STARTING INSTALLATION. ASSISTANCE IS RECOMMENDED. DRILLING IS
REQUIRED. CUTTING OF PLASTIC BED LINER (IF EQUIPPED) MAY BE REQUIRED.
1. Select the passenger/right Mounting Bracket. Attach the Bracket to the Headache Rack with the included (2) 12mm Hex Bolts, (4) 12mm Flat Washers, (2) 12mm Lock Washers and (2) 12mm Hex
Nuts, (Figure 1) . Do not tighten hardware. Repeat this Step to attach the driver/left Mounting Bracket.
2. With assistance, carefully place the Headache Rack onto the approximate mounting position at the front end of the truck bed. Line up the forward end of the Brackets with the end of the bed but leave clearance between the Rack and the back of the cab.
a. Determine if the forward mounting holes in the Brackets line up with the front stake pockets.
NOTE : On some vehicles, the front stake pocket may be covered with a plastic bed cap.
Remove or cut out the cover as required to gain access to the stake pocket, (Figure 2) .
b. On most vehicles, the forward holes will line up with or close to the forward stake pockets. On these vehicles, select (1) 10mm "J" Bolt and (1) 12mm Flat Washer, (Figure 3) . Slide the Flat
Washer over the "J" Bolt down to the head on the bolt, (Figures 4 & 5) . Insert the "J" Bolt into the hole in the side of the stake pocket and up and out the hole in the Bracket, (Figure 5) .
Secure the Bracket to the "J" Bolt with (1) 10mm Small Flat Washer, (1) 10mm Lock Washer and (1) 10mm Hex Nut, (Figure 4) . Do not fully tighten hardware at this time. c. Repeat to install the driver/left side "J" Bolt. d. Skip to Step 3 for additional drilling and bolting information. IMPORTANT : On some models, the forward holes will not line up with the stake pockets. If the Brackets do not line up correctly with the stake pockets or the "J" Bolt does not reach up to the Bracket, the "J" Bolts will not be used and proceed to Step 3 . Do not attach the Headache Rack with only the "J" Bolts!
Additional hardware is required and drilling is mandatory.
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UNIVERSAL HEADACHE RACK
MID SIZED TRUCKS (EXCL TOYOTA TACOMA)
3. With the Headache Rack properly positioned on the top of the bed, locate the best location to drill. Use the provided holes in the Brackets if possible, (Figure 6) . Do not drill the top of the bed until you have made absolutely sure that you can gain access to the bottom of the mounting locations. (Figure 7) . a. Use the pre-punched holes in the Bracket if possible. If you are using the "J" Bolts, only mark the rear mounting location on the top of the bed, (Figure 6 & 8) . If "J" Bolts are not used, mark the forward and rear mounting locations, (Figure 6) . b. Each mounting location on the Bracket has (2) holes. Use the holes in the center if possible, to better support for the Rack. The holes toward the inner edge are provided for models with inner panels on the bed and a narrow mounting surface along the inner edge.
4. Once all locations have been checked and the holes marked on the top of the bed, remove the
Headache Rack assembly. Drill the required holes as marked with a 7/16" drill bit. Bolt the Bracket to each mounting hole with (1) 10mm Hex Bolt, (2) 10mm Flat Washers, (1) 10mm Lock Washer and (1)
10mm Hex Nut, (Figure 9) . IMPORTANT : To help support the Headache Rack, large 10mm Flat
Washers have been provided. Use the larger Washers under the top of the bed if possible. Smaller
10mm Flat Washers have also been provided if there is insufficient room.
5. The provided mounting holes in the Brackets will allow installation on most but not all vehicles. If the holes are not in the correct location for your particular model, drill new mounting holes through the
Bracket and top of the bed as necessary for the best possible fit. Additional hardware has been included, use is optional.
6. Center the Headache Rack on the truck, check the alignment and tighten all hardware.
Do periodic inspections to the installation to make sure that all hardware is secure and tight.
To protect your investment , wax this product after installing. Regular waxing is recommended to add a protective layer over the finish. Do not use any type of polish or wax that may contain abrasives that could damage the finish.
Front (2) 12mm Hex Bolts
(4) 12mm Flat Washers
(2) 12mm Lock Washers
(2) 12mm Hex Nuts
(Fig 1) Passenger/right side Bracket attached to Headache Rack assembly
Fig 2
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UNIVERSAL HEADACHE RACK
MID SIZED TRUCKS (EXCL TOYOTA TACOMA)
(Fig 3) 10mm "J" Bolt w/12mm Flat Washer
(Fig 5) Use the "J" Bolt to secure the front mounting holes on the Bracket to the stake pocket if possible. Do not drill any mounting holes until after all mounting locations are checked for clearance
(Fig 4) Use the "J" Bolt to secure the front mounting holes on the Bracket to the stake pocket if possible. Do not drill any mounting holes until after all mounting locations are checked for clearance
(Fig 6) If the forward hole in the Bracket does not line up with the stake pocket or the J Bolt will not fit properly, mark the locations on the top of the bed and drill 7/16” holes as required to attach the
Bracket directly to the top of the bed.
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(Fig 7) Before drilling any holes through the top of the bed, check the bottom of the top edge of the bed for hardware clearance.
10mm J-Bolt
12mm Large Flat Washer (on J-Bolt)
10mm Small Flat Washer
10mm Lock Washer
10mm Hex Nut
UNIVERSAL HEADACHE RACK
MID SIZED TRUCKS (EXCL TOYOTA TACOMA)
10mm Hex Bolt
10mm Small Flat Washer (top)
10mm Small Flat Washer (bottom) or
10mm Large Flat Washer (bottom)
10mm Lock Washer
10mm Hex Nut
(Fig 8) Bracket attached with
J-Bolt and Hex Bolt
10mm Hex Bolt
10mm Small Flat Washer (top)
10mm Small Flat Washer (bottom) or
10mm Large Flat Washer (bottom)
10mm Lock Washer
10mm Hex Nut
(Fig 9) Bracket attached with Hex Bolts only
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